Patent application title: Architectural Covering and Method

Abstract:

The present application is directed to an architectural cover for securing
to a support surface comprising: a frame defining a perimeter; a panel
overlying a portion of the frame to form an exterior side of the cover
and an interior side of the cover; the frame further comprising (a) a
main body configured to attach to the panel via a fastening means, and
(b) a lip defined by a first surface configured to receive a securing
means, and a second surface configured to abut the support surface; the
lip further comprising an outer edge defining a perimeter of the cover
and an inner edge defining an inner perimeter of the frame, the perimeter
of the inner edge configured to abut the support surface when the
architectural cover is secured to the support surface.

Claims:

1. An architectural cover for securing to a support surface comprising:a
frame defining a perimeter;a panel overlying a portion of the frame to
form an exterior side of the cover and an interior side of the cover;the
frame further comprising (a) a main body configured to attach to the
panel via a fastening means, and (b) a lip defined by a first surface
configured to receive a securing means, and a second surface configured
to abut the support surface;the lip further comprising an outer edge
defining a perimeter of the cover and an inner edge defining an inner
perimeter of the frame, the perimeter of the inner edge configured to
abut the support surface when the architectural cover is secured to the
support surface.

2. The architectural cover of claim 1, wherein the frame is assembled from
three or more longitudinal frame members of unequal lengths.

3. The architectural cover of claim 1, wherein the frame further includes
a first grooved section configured to receive a decorative joint member
therethrough.

4. The architectural cover of claim 1, wherein the frame further includes
a bend up to about 90.degree. forming a landing surface.

5. The architectural cover of claim 1, wherein the lip further comprises a
first surface for receiving a securing means.

6. The architectural cover of claim 5, wherein the lip further comprises a
second surface.

7. The architectural cover of claim 4, wherein the first surface further
comprises a scored region.

9. The architectural cover of claim 1, wherein the panel forms an end cap
over an edge of the support surface.

10. A system for forming a continuous barrier on a support surface
comprising:a plurality of architectural covers, the architectural covers
being secured adjacent one another on the support surface forming joints
there between;wherein each architectural cover forms an independent
relationship with the support surface when secured to the support
surface.

11. The system of claim 10, wherein adjacent covers have centers that are
different distances from the top and bottom edges of the support surface.

12. The system of claim 10, further including decorative joint members
inserted at the joints between the architectural covers.

13. The system of claim 10, wherein each architectural cover comprises a
different size, different shape and different number of sides.

14. The system of claim 13, wherein each architectural cover can be
secured to the support surface using like securing means without regard
to the size and shape of the architectural covers.

15. A system for forming a continuous barrier on a support surface
comprising:two or more architectural covers, each cover having a frame
and a panel, wherein the frame comprises three or more sides defining a
perimeter, the frame being securable to the support surface; the panel
overlying the frame to form an exterior side of the cover and an interior
side of the cover;one or more decorative joint members;wherein the two or
more covers are secured adjacent one another on the support surface
forming joints there between;wherein the two or more covers form an
independent relationship with the support surface when secured to the
support surface; andwherein the decorative joint members are inserted at
the joints between the frames of adjacent covers to conceal the joints
from view.

16. The system of claim 15, further comprising sealing members disposed
between the covers and the support surface when the covers are secured to
the support surface.

17. The system of claim 15, wherein each architectural cover comprises a
different size, different shape and different number of sides.

18. The system of claim 15, wherein the architectural covers may be
secured to the support surface in a non-sequential manner.

19. A method for forming a continuous barrier on a support surface using a
plurality of architectural covers, the method comprising:providing a
plurality of architectural covers, each architectural cover comprising a
frame defining a perimeter, and a panel overlying the frame to form an
exterior side of the cover and an interior side of the cover; the frame
further including a main body configured to attach to the panel via a
fastening means, and a lip defined by a first surface configured to
receive a securing means, and a second surface configured to abut the
support surface; the lip further comprising an outer edge defining a
perimeter of the cover and an inner edge defining an inner perimeter of
the frame, the perimeter of the inner edge configured to abut the support
surface when the architectural cover is secured to the support
surface;randomly securing successive architectural covers directly to the
support surface wherein the outer edges of each architectural cover share
common borders with the outer edges of adjacent architectural covers.

20. The method of claim 19, wherein the support surface is pre-marked to
form areas having various shapes of varying sizes each configured for
placement of a corresponding cover.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002]Not applicable.

FIELD OF THE APPLICATION

[0003]The application relates generally to architectural covers to be
applied to surfaces such as building walls and the like.

BACKGROUND

[0004]Architectural panels are used as cladding elements in architecture
and building construction (1) to improve the aesthetics of both exterior
and interior surfaces of buildings and other structures, (2) to reduce
costs related to construction, (3) to lighten the weight of construction
materials, (4) to improve the durability of construction, and (5) to
reduce long term maintenance cost and for weather protection.

[0005]Known attachment options for securing architectural panels to a
surface requires that each panel necessarily contacts at least one
adjacent panel or contacts a sub-frame in order to secure, align and/or
seal the panels to a surface. Thus, the attachment of a single panel to a
surface is dependent on its relationship with an adjacent panel or
sub-frame. For example, architectural panels may be secured to a surface
by first securing a dedicated sub-frame to the surface followed by
fastening individual architectural panels to the sub-frame. Another known
technique involves securing individual panels directly to a surface in a
sequential overlapping and/or interlocking manner.

[0006]A typical sub-frame includes a grid like structure having parallel
rows and columns of equidistant elongated members pre-fastened to the
surface. Thus, the distance between adjacent elongated members determines
the size of panels to be attached thereto. In addition, the orientation
of the sub-frame necessarily determines the directional alignment and
orientation of the panels on a surface. In addition, sub-frames often
have multiple parts that must be assembled, aligned and leveled, which
can be both time and labor intensive. Likewise, the failure of individual
panels often results from the failure of the sub-frame itself. The grid
like configuration of a sub-frame also means that damage to one
particular panel may cause damage to adjacent panels. For example, water
leakage along the interior side of a particular panel may spread to the
interior side of adjacent panels.

[0007]In the prior art, when attached in a sequential overlapping or
interlocking manner, the perimeter of each successive panel overlaps or
interlocks a portion of the frame of the previous panel in a sequential
and directional manner, similar to applying shingles along a rooftop. In
addition, as each successive row or column of panels is applied to the
surface, a portion of the panel of each successive row or column
necessarily overlaps a portion of the panel making up the preceding row
or column. Like shingles, the overlapping panel configuration is
intended, in part, to protect the target surface against water
penetration, to maximize thermal efficiency, to conceal the surface from
view, and to ensure proper alignment of the panels on the surface, i.e.,
in rows or columns. Unfortunately, the sequential application of panels
means that in order to remove and/or replace a particular panel, all
successive panels must be first removed to gain access to that particular
panel. Thereafter, panels must be reapplied to the surface in a
sequential manner to re-cover the surface, which is time consuming and
labor intensive.

[0008]Hence from the foregoing, it will be appreciated that there is a
need for a panel design that enables individual panels to be
independently secured to a surface in a random manner to form a
continuous barrier across a surface without affecting other panels that
are secured to the same surface.

SUMMARY

[0009]The present application provides an architectural cover for securing
to a support surface comprising: a frame defining a perimeter; a panel
overlying a portion of the frame to form an exterior side of the cover
and an interior side of the cover; the frame further comprising (a) a
main body configured to attach to the panel via a fastening means, and
(b) a lip defined by a first surface configured to receive a securing
means, and a second surface configured to abut the support surface; the
lip further comprising an outer edge defining a perimeter of the cover
and an inner edge defining an inner perimeter of the frame, the perimeter
of the inner edge configured to abut the support surface when the
architectural cover is secured to the support surface.

[0010]The present application also provides a system for forming a
continuous barrier on a support surface comprising: a plurality of
architectural covers, the architectural covers being secured adjacent one
another on the support surface forming joints there between; wherein each
architectural cover forms an independent relationship with the support
surface when secured to the support surface.

[0011]The present application also provides a system for forming a
continuous barrier on a support surface comprising: two or more
architectural covers, each cover having a frame and a panel, wherein the
frame comprises three or more sides defining a perimeter, the frame being
securable to the support surface; the panel overlying the frame to form
an exterior side of the cover and an interior side of the cover; one or
more decorative joint members; wherein the two or more covers are secured
adjacent one another on the support surface forming joints there between;
wherein the two or more covers form an independent relationship with the
support surface when secured to the support surface; and wherein the
decorative joint members are inserted at the joints between the frames of
adjacent covers to conceal the joints from view.

[0012]The present application also provides a method for forming a
continuous barrier on a support surface using a plurality of
architectural covers, the method comprising: providing a plurality of
architectural covers, each architectural cover comprising a frame
defining a perimeter, and a panel overlying the frame to form an exterior
side of the cover and an interior side of the cover; the frame further
including a main body configured to attach to the panel via a fastening
means, and a lip defined by a first surface configured to receive a
securing means, and a second surface configured to abut the support
surface; the lip further comprising an outer edge defining a perimeter of
the cover and an inner edge defining an inner perimeter of the frame, the
perimeter of the inner edge configured to abut the support surface when
the architectural cover is secured to the support surface; randomly
securing successive architectural covers directly to the support surface
wherein the outer edges of each architectural cover share common borders
with the outer edges of adjacent architectural covers.

BRIEF DESCRIPTION OF THE FIGURES

[0013]FIG. 1 illustrates the random placement of four sided architectural
covers onto a support surface.

[0014]FIG. 2 illustrates a perspective view of an architectural cover
including the exterior side of the cover.

[0015]FIG. 3 illustrates a perspective view of an architectural cover
including the interior side of the cover.

[0017]FIG. 5A illustrates a perspective view of adjacent architectural
covers including a cross section of two adjacent covers.

[0018]FIG. 5B illustrates a cross-sectional perspective view of adjacent
architectural covers including attachment of the panels to the frames and
attachment of the frames to a support surface.

[0019]FIG. 6 illustrates a cross-sectional side view of an architectural
cover attached at the base of a support surface.

[0020]FIG. 7 illustrates a panel configuration including a top cap on a
support surface.

[0021]FIG. 8 illustrates a cross-sectional view of an architectural cover
attached to the outside corner of a support surface.

[0022]FIG. 9 illustrates a cross-sectional view of the attachment of
architectural covers at an inside corner of a support surface.

[0023]FIG. 10 illustrates a cross-sectional view of an architectural cover
at a wall jamb.

[0024]FIG. 11 illustrates an embodiment of three sided architectural
covers forming a continuous barrier on a surface.

[0025]FIG. 12 illustrates an embodiment of non-uniform shaped
architectural covers of various sizes forming a continuous barrier on a
surface.

[0026]FIG. 13 illustrates an embodiment of various architectural covers
forming a continuous barrier on a non-rectangular support surface.

DESCRIPTION

[0027]It has been found that one or more architectural covers, each
comprising a frame defining a perimeter of three or more sides and a
panel overlying a portion of the frame, can be secured to a support
surface as cladding to form a continuous barrier across the support
surface wherein the architectural covers are secured to the support
surface independent of a sub-frame and in a manner other than by
sequentially contacting architectural covers in an overlapping or
interlocking manner. It has also been found that architectural covers
comprising a different number of sides and various sizes can be used to
form a continuous barrier across a support surface. It has further been
found that the frame of the architectural cover can be configured to
increase the load bearing characteristics of the architectural cover.
Heretofore, such a desirable achievement has not been suitably
accomplished. Accordingly, the novel cover and method of this application
measure up to the dignity of patentability and therefore represent a
patentable concept.

[0028]Before describing the invention in detail, it is to be understood
that the present architectural cover and method are not limited to
particular embodiments. It is also to be understood that the terminology
used herein is for the purpose of describing particular embodiments only,
and is not intended to be limiting. The phrases "independent
relationship," "independently secure," and variations thereof refer to
the ability to releasably secure and/or seal an architectural cover to a
support surface without necessarily contacting an adjacent architectural
cover and/or a sub-frame. The term "joint" refers to space between
adjacent panels, more particularly, the space between the return portion
of the panels. The phrase "continuous barrier" refers to one or more
covers completely covering a target surface. The phrase "self align" and
variations thereof refers to the ability to align an architectural cover
on a support surface at a desired orientation without necessarily
contacting an adjacent architectural cover.

[0029]In one aspect, the present application provides a means for
individual architectural covers to be removed from a support surface and
replaced without disturbing adjacent architectural covers secured to the
support surface.

[0030]In another aspect, the present application provides a means for
providing a more permanent seal across a support surface.

[0031]In another aspect, the present application provides a method for
forming a continuous barrier across a support surface by providing one or
more architectural covers less expensive to install than known
techniques.

[0032]In another aspect, the present application provides a method for
forming a continuous barrier across a support surface including providing
architectural covers that may be installed more quickly than known
techniques.

[0033]In another aspect, the present application eliminates the necessity
of a dedicated framing scheme or common intermittent attachment between
architectural covers.

[0034]In still another aspect, the present application provides an
architectural cover comprising a frame having a load bearing surface
abutting a support surface when secured to the support surface.

[0035]In still another aspect, the present application provides an
architectural cover that is light in weight.

[0036]In another aspect, the present application provides an architectural
cover configuration whereby a plurality of architectural covers can be
secured to a support surface using like securing means without regard to
the size and shape of the architectural covers.

[0037]In yet another aspect, the present application provides an
architectural cover resistant to hurricane type forces when secured to a
support surface as described herein.

[0038]In another aspect, the present application provides an architectural
cover that can be used as part of either a dry seal system or a wet seal
system.

[0039]In another aspect, the present application provides one or more
architectural covers forming a barrier across a support surface whereby
the covers are secured to the support surface in a non-aligned and/or
non-leveled manner.

[0040]In another aspect, the present application provides a system of
architectural covers that may be secured to a support surface in a
non-sequential and/or non-directional manner.

[0041]In another aspect, the present application provides a system of
architectural covers for forming a continuous barrier across a support
surface wherein the covers may comprise different sizes, different shapes
and various numbers of sides.

[0042]In another aspect, the present application provides a system of
architectural covers for forming a continuous barrier on a support
surface wherein the outer edges of adjacent covers are parallel while the
remaining edges of the covers are neither parallel nor perpendicular to
one another.

[0043]In another aspect, the present application provides a method for
forming a continuous barrier across a rectangular support surface using a
plurality of architectural covers having three or more sides, whereby
adjacent covers have centers that are different distances from the top
and bottom edges of the support surface.

[0044]In another aspect, the present application provides a method of
sealing a support surface by providing a plurality of independent
architectural covers each securably sealed to the support surface in a
manner effective for each of the architectural covers to collectively
seal the support surface to form a continuous sealed barrier across the
support surface.

[0045]In another aspect, the present application provides a system of
architectural covers whereby any load placed on a particular cover when
secured to a support surface does not affect any other cover secured to
the same support surface.

[0046]The various characteristics described above, as well as other
features, will now be described with reference to the accompanying
drawings, wherein like reference numerals are used for like features
throughout the several views. It is to be fully recognized that the
different teachings of the embodiments disclosed herein may be employed
separately or in any suitable combination to produce desired results.

Brief Description of the Architectural Cover

[0047]The architectural cover described herein suitably comprises a
configuration effective for one or more architectural covers to be
secured to a support surface independent of any other architectural cover
and in any random order effective for forming a continuous barrier across
a target support surface. In an alternative embodiment, the architectural
cover described herein may be independently secured to a target support
surface in a manner effective to form a seal between the architectural
cover and the support surface.

[0048]With reference to FIG. 1, a simplified support surface 100 is shown
including a plurality of architectural covers 10 randomly and
independently secured to the support surface 100. As FIG. 1 exemplifies,
it is herein contemplated that individual architectural covers 10 (herein
referred to as "cover") may be secured to a support surface 100 to form a
continuous barrier on the support surface 100 in any random order and
without regard to the orientation of any other cover to be secured to the
support surface 100.

[0049]For example, in one embodiment a first cover 10 may be secured near
an edge of a support surface 100 whereby the alignment of the first cover
10 in relation to the support surface 100 is effective to further align a
second cover 10 secured to the support surface 100 adjacent the first
cover 10. Likewise, all successive covers 10 to be secured to the support
surface 100 may be aligned on the support surface 100 based on the
alignment of a preceding adjacent cover 10. In another embodiment, a
plurality of covers 10 may be randomly placed on a support surface 100 in
any order and arrangement until the covers 10 form a barrier across the
support surface 100. In still another embodiment, a support surface 100
can be pre-marked indicating the exact location upon which each cover 10
is to be secured to the support surface 100 to form a barrier across the
support surface 100.

[0050]FIG. 2 is an illustration of an exterior side of a simplified cover
10. As shown, the cover 10 comprises a frame 12 defining a perimeter of
the cover 10, and a panel 14 operationally configured to overlie a
portion of the frame 12. In this particular embodiment, the frame 12
includes four substantially equidistant sides defining a perimeter
wherein the panel 14 is folded over a portion of the frame 12 to form an
exterior side of the cover 10 and an interior side of the cover 10.
Suitably, the cover 10 described herein can be fabricated using route and
return methodology known to persons of ordinary skill in the art,
although other methods may be incorporated.

[0051]Suitably, the portion of the panel 14 folded over the frame 12 is
releasably attached to the frame 12 by one or more fastening means 16,
which allows for replacement of the panel 14 portion if necessary.
Suitable fastening means 16 include, but are not necessarily limited to
conventional screws, rivets, bolt type fasteners, and combinations
thereof. Suitable screws include, but are not necessarily limited to
stainless steel screws of T3 or T5 grade material. In addition, a sealant
may be applied to the cover 10 to form a seal between the panel 14 and
the frame 12. Suitable sealants include but are not necessarily limited
to silicone, structural silicone, polyurethane, rubber, elastomer, and
combinations thereof.

[0052]Referring now to FIG. 3, an interior side of a simplified four sided
cover 10 is illustrated, including the interior side of both the frame 12
and panel 14. Depending on the desired shape of the cover 10, a suitable
frame 12 may be formed from three or more longitudinal frame members each
comprising a surface configuration including at least a main body 12a
portion for attaching to the panel 14, and a lip 12b portion for
attachment to a support surface 100.

[0053]In particular, the lip 12b is suitably defined by a first surface
13a (as illustrated in FIG. 2) and a second surface 13b (as illustrated
in FIG. 3). The lip 12b also comprises an outer edge 18a defining an
outer perimeter of both the frame 12 and the cover 10, and an inner edge
18b defining an inner perimeter of the frame 12.

[0054]In one embodiment, the lip 12b may comprise one or more apertures
(not shown) each operationally configured to receive a securing means 20
on the first surface 13a for independently securing a cover 10 directly
to a support surface 100. In another embodiment, the first surface 13a of
the lip 12b may comprise a scored region 30 (see FIG. 2) operationally
configured to guide a user as to proper placement of the securing means
20 on the first surface 13a. In particular, the scored region 30 provides
a user with a starting location along the first surface 13a upon which
one or more securing means 20 may be directed through the lip 12b.
Suitably, the scored region 30 comprises a groove or series of grooves
along the first surface 13a set apart from the main body 12a a distance
effective for the securing means 20 to be directed through the lip 12b
without contacting the main body 12a of the frame 12. Thus, the lip 12b
suitably extends perpendicularly from the main body 12a a distance
effective for receiving a securing means 20 having a width up to about
the width of the first surface 13a.

[0055]The longitudinal frame members may include extruded material
manufactured in various lengths, whereby a user may cut the extruded
frame material into three or more sections of desired lengths and edge
mitered to any angle to form a desired size and shape of cover 10. An
L-type bracket (not shown) may also be used at the junction between frame
members to hold the frame members together at the mitered edges.
Suitably, the L-type bracket is set on the interior side of the cover 10
whereby one or more fastening means 16 penetrate the panel 14, frame 12
and L-type bracket to form a cover 10.

[0056]Suitably, the one or more securing means 20 are operationally
configured to independently secure the cover 10 to a support surface 100
in a manner effective for up to about the entire second surface 13b to
abut the support surface 100. In a particularly advantageous embodiment,
the inner edge 18b of the lip 12b abuts the support surface 100 when the
cover 10 is independently secured to the support surface 100. In another
particularly advantageous embodiment, the outer edge 18a and inner edge
18b of the lip 12b abut the support surface 100 when the cover 10 is
independently secured to the support surface 100.

[0057]The one or more securing means 20 may include, but are not
necessarily limited to mounting gear such as conventional screws, nails,
anchor studs, and combinations thereof. Suitable screw materials include,
but are not necessarily limited to ferrous metals, non-ferrous metals,
plastics and combinations thereof. In one embodiment, the screw may
include a sheet metal screw such as a stainless steel screw of T3 or T5
grade material. In addition, the screws may comprise a hex shaped head to
facilitate the placement of the screws within a support surface 100. The
screw head may further comprise an Allen, Phillips or straight slot
arrangement for directing the screws. Typical commercially available
screws include a helical shape thread in a downward spiraling direction
effective to penetrate a support surface 100 upon a clockwise rotation.
Subsequently, when removing a cover from a support surface 100, the
screws can be removed from the support surface 100 by reverse rotation,
i.e., counter clockwise.

[0058]The panel 14 portion of the cover 10 is suitably constructed from
one or more materials to form (1) an exterior surface of the cover 10
comprising any combination of desired aesthetic characteristics such as
color, texture and surface design, and (2) an interior surface
operationally configured to attach to the frame 12. Suitably, the panel
14 is constructed from one or more materials capable of being shaped,
cut, and/or bent as necessary to form a particular cover 10. Likewise,
the panels 14 may be flat, curved, roll formed, perforated, or hot
welded. Suitably, the panel 14 comprises a sheet material made from one
or more metals, composite materials, plastics, and combinations thereof.
Suitable metals include, but are not necessarily limited to ferrous
metals and non-ferrous metals. Although not necessarily limited to
particular metals, suitable ferrous metals include for example, irons
including alloys of iron, i.e., titanium and steels including stainless
steel. Suitable non-ferrous metals include for example, aluminum, tin,
copper, and brass. Suitable composite materials include, but are not
necessarily limited to particle board, plywood, concrete, stucco,
fiberboard, and sheetrock.

[0059]In one suitable embodiment, the panel 14 comprises a metal composite
material including a thermoplastic core layer sandwiched between layers
of metal. In a particularly advantageous embodiment, the panel 14 is an
aluminum composite material including two layers of aluminum separated by
a polyethylene core layer.

[0060]Depending on the application, the panel 14 material may be
prefinished, for example, by coil coating or electrostatic paint. In
addition, other additives may be incorporated into the panel 14 core as
desired. Suitable additives include, but are not necessarily limited to
basalt and synthetic fibers such as KEVLAR®. Although the cover 10
may be built to scale, a suitable panel 14 for architectural applications
comprises a thickness from about 2.0 mm (about 0.08 inches) to about 7.0
mm (about 0.24 inches). In a particularly advantageous embodiment, a
panel 14 comprises a thickness of about 4.0 mm (about 0.16 inches)
including two layers of aluminum separated by a polyethylene material,
wherein each layer of aluminum comprises a thickness of about 0.50 mm
(about 0.020 inches). In addition, an exemplary panel 14 may comprise a
weight of about 0.8 lb/ft2 or more, although panels 14 comprising
lighter weights are also contemplated.

[0061]Although it is herein contemplated that the cover 10 may comprise
various configurations, including non-planar configurations, a suitable
cover 10, when secured to a support surface 100, comprises a panel 14
having (1) a first outer surface 15a defining a plane substantially
parallel to the plane defining the support surface 100, and (2) a second
surface 15b defining a plane substantially perpendicular to the plane
defining the support surface 100. The second surface 15b of the panel 14
is also referred to herein as the "return portion" of the panel 14.

[0062]The frame 12 is suitably constructed from three or more rigid or
semi-rigid longitudinal frame members of equal or unequal lengths that
are operationally configured to maintain the cover 10 in a secured
position on a support surface 100. As previously stated, the frame 12 is
suitably constructed from one or more extruded materials capable of being
further shaped, cut, and/or bent to form a particular shaped cover
10--the frame 12 members having a greater load capacity once formed into
a cover 10. Suitable materials include, but are not necessarily limited
to ferrous and non-ferrous metals, high density plastics, and ultra-high
molecular weight polyethylene. Suitably metals include for example steel,
aluminum, titanium, and tin. In a particularly advantageous embodiment,
the frame 12 comprises extruded 6063 aluminum that is heat treated to a
T5 condition.

[0063]Details focused on the relationship between adjacent covers 10 when
secured to a support surface is illustrated in FIG. 4. As shown, each
cover 10 comprises like frames 12, including a main body 12a and lip 12b
whereby the main body 12a comprises a length effective to form a cavity
on the interior side of the cover 10 within the inner perimeter of the
frame 12 (see FIG. 3). Although the cover 10 can be built to scale, in
common architectural applications, a suitable frame 12 comprises a main
body 12a having a length of about 1.8 cm (about 0.75 inches) or more. As
stated above, a suitable panel 14 comprises a thickness from 2.0 mm to
about 7.0 mm. Thus, when independently secured to a support surface 100,
a suitable cover 10 extends out from the support surface 100 about 2.54
cm (about 1.00 inches) or more.

[0064]The main body 12a suitably comprises a first mating surface lying
substantially perpendicular to the plane of the support surface 100 for
attachment of the return portion of the panel 14 to the main body 12a.
Likewise, the main body 12a may comprise a distal edge terminating
directionally substantially perpendicular to the plane of the support
surface 100. In the alternative, the main body 12a may comprise a distal
edge terminating directionally substantially parallel to the plane of the
support surface 100--as shown in FIG. 4. As shown, the main body 12a may
comprise a bend up to about 90° for forming a landing surface 12c
for contacting a portion of the interior of a panel 14. As FIGS. 5A and
5B demonstrate, the panel 14 may not necessarily contact the landing
surface 12c. For example, the interior side of a panel 14 will only
contact the landing surface 12c when the depth of the panel returns are
less than the length of the main body 12a of the frame 12. Thus, when
deep sided panels are used, the interior side of the panel 14 is raised
above the landing surface 12c. As stated previously, a sealant may be
applied to the cover 10 to form a seal between the panel 14 and the frame
12. Suitably, a sealant is applied to either the first mating surface of
the main body 12a or the landing surface 12c prior to attachment of the
panel 14.

[0065]Each main body 12a of the frame 12 may further include at least a
first grooved section 22 running the length of the frame 12 configured to
receive a decorative joint member 23 therethrough. As FIG. 4 illustrates,
as two adjacent covers 10 are secured to a support surface 100 to form a
joint there between, the first grooved sections 22 of adjacent frames 12
are aligned to receive a substantially straight decorative joint member
23 therethrough whereby the plane of the decorative joint member 23 is
substantially parallel to the plane of the support surface 100. In one
embodiment, the first grooved section 22 may comprise a curved surface
effective to increase the load bearing capacity of the frame 12 as
compared to a first grooved section 22 having a cornered surface.
However, the first grooved section 22 may comprise a cornered surface or
other surface configuration as desired.

[0066]The first grooved section 22 suitably runs a length up to about the
length of the frame 12 to receive a decorative joint member 23
therethrough. Mostly used for aesthetic purposes, a plurality of
decorative joint members 23 may be inserted at the joints into the first
grooved section 22 of each frame 12 to conceal the joints. For example,
when a plurality of rectangular covers 10 are used to form a continuous
barrier on a support surface 100, a plurality of decorative joint members
23 may be inserted vertically and horizontally at the joints between the
frames 12 of adjacent covers 10 to conceal the joints from view.

[0067]For ease of on-site installation, decorative joint members 23 may be
made from sheet material similarly to the one or more panels 14. Thus,
sheet material may be stored on-site and cut into strips to form
decorative joint members 23 comprising lengths about equal to the height
of the support surface 100. The decorative joint members 23 may then be
inserted along the vertical joints through the grooved sections 22 while
shorter decorative joint members 23 may be inserted along the horizontal
joints between the vertically placed decorative joint members 23 to
conceal the horizontal joints from view. In another embodiment,
decorative joint members 23 comprising a length about equal to the width
of the support surface 100 may be inserted along the horizontal joints
through the grooved sections 22 while shorter decorative joint members 23
may be inserted along the vertical joints between the horizontally placed
decorative joint members 23 to conceal the joints from view.

[0068]Although not necessarily limited to particular materials, a suitable
decorative joint member 23 may be constructed from one or more materials
similar to the materials forming the panel 14. Although the decorative
joint members 23 do not necessarily have to be constructed from like
materials as the one or more panels 14, a particular user may find it
aesthetically pleasing to use similar materials for visual consistency.
Thus, for example, the decorative joint member 23 and one or more panels
14 may be constructed from metal composite material. In another suitable
embodiment, the decorative joint member 23 may be constructed from
stainless steel while the corresponding panels 14 are constructed from
metal composite material.

[0069]With further reference to FIG. 4, the lip 12b of the frame 12 may be
configured so that up to about the entire second surface 13b of the lip
12b abuts the support surface 100. Although the second surface 13b of the
lip 12b and corresponding support surface 100 are shown as having
substantially flat surfaces, it is herein contemplated that the second
surface 13b of the lip 12b may be configured to abut a non-flat support
surface 100. For example, the second surface 13b of the lip 12b may be
curved to accommodate a corresponding curved support surface 100.

[0070]As FIG. 4 further illustrates, each frame 12 may comprise a second
grooved section 24 at the interface between the main body 12a and the lip
12b. In one embodiment, the second grooved section 24 may comprise a
curved surface. In another embodiment, the second grooved section 24 may
comprise a cornered surface or other surface configuration as desired. In
still another embodiment, the frame 12 may not include a second grooved
section 24, but may instead include a solid core section thereby forming
a thicker lip 12b.

[0071]As stated above, the lip 12b suitably extends perpendicularly from
the main body 12a a distance effective to receive a securing means 20
comprising a width up to about the width of the first surface 13a.
Although the lip 12b is not limited to a particular size, the total width
of adjacent lips 12b, i.e., the width of a joint, is suitably less than
the width of the cover 10. Thus, the distance between the second surfaces
15b of adjacent panels 14 is less than the width of the first surface 15a
of the panel 14 (see FIG. 5A). Accordingly, the width of a decorative
joint member 23 is also less than the width of the cover 10. In addition,
the outer edge 18a is suitably configured so that adjacent covers 10 can
contact one another lengthwise, as discussed in more detail below.

[0072]The inner edge 18b defining the inner perimeter of the frame 12 may
also comprise various configurations as desired. For instance, the inner
edge 18b may be cornered, pointed, curved or rounded off. In a
particularly advantageous embodiment, the inner edge 18b defining the
inner perimeter of the frame 12 is rounded off--as shown for example in
FIGS. 4, 5B and 6. Suitably, a rounded off inner edge 18b provides a
cover 10 with superior load bearing capacity over other inner edge 18b
configurations when the cover 10 is secured to a support surface 100. For
example, the stress concentration placed on a 90° squared off
inner edge 18b is greater than the stress concentration placed on a
rounded inner edge 18b. Thus, it is desirable that the entire perimeter
of the inner edge 18b be rounded off and configured to abut the support
surface 100 during operation of the cover 10.

[0073]For the purposes of this application, a continuous barrier may be
formed on a support surface 100 using one or more covers 10--depending on
the total surface area of the support surface 100 in relation to the size
of the cover(s) 10 to be secured thereto. In an embodiment incorporating
a plurality of covers 10, the outer edges 18a of a particular cover 10
may be self aligned near or against the outer edges 18a of one or more
adjacent covers 10 wherein the outer edges 18a of adjacent covers 10
share common borders. Thus, the outer edge 18a of a side of a second
cover 11 may be self aligned flush against the outer edge 18a of a side
of a first cover 10 forming a joint between the covers 10--as illustrated
in FIGS. 5A and 5B. In another embodiment, the outer edge 18a of a side
of a second cover 11 may be aligned near the outer edge 18a of a side of
a first cover 10 to form a joint between the covers 10.

[0074]Although the outer edges 18a of the frames 12 are not necessarily
limited to a particular shape, suitable outer edges 18a of adjacent
covers 10 may contact one another lengthwise. In another embodiment
comprising adjacent covers 10 with outer edges 18a aligned only near one
another, the outer edges 18a are suitably configured to at least contour
one another lengthwise. As the figures illustrate, the lips 12b suitably
comprise straight outer edges 18a, although non-straight outer edges 18a
are also herein contemplated.

[0075]To form a continuous barrier across a support surface 100 a
plurality of covers 10 may be secured to the support surface 100 by
aligning the outer edges 18a of a second cover 11 with the outer edges of
a first cover 10 that was randomly secured to the support surface 100.
Thus, it is herein contemplated that a first cover 10 may be aligned in
any orientation and secured to a support surface 100 at any location to
form a continuous barrier across the support surface 100. For example,
when employing a plurality of square shaped covers 10 to be secured to a
rectangular support surface 100, the first cover 10 to be secured may be
squared or otherwise aligned along the x-y axis of the support surface
100. Thereafter, each successive cover 10 may be aligned along the x-y
axis by self-aligning the outer edge 18a of each successive cover 10
adjacent the outer edge 18a of a preceding cover 10. In another
embodiment wherein the support surface 100 is not rectangular, covers 10
may still be leveled across the majority of the support surface 100 with
dissimilar covers 10 used to form a barrier across the remaining support
surface 100--as shown in FIG. 13.

[0076]Referring now to FIG. 6, an embodiment of a simplified cover 10
abutting a base surface 110 is shown. When secured to a substantially
vertical support surface 100, i.e., a building exterior, each of the
lowermost covers 10 may be secured to the support surface 100 to form a
termination joint along the base. As illustrated, the outer edge 18a of
the lip 12b suitably abuts the base surface lengthwise, as a securing
means 20 is inserted through the lip 12b to secure the frame 12 to the
support surface 100. A sealant may be applied to the termination joint as
desired.

[0077]Uppermost covers 10 may terminate along a support surface 100 by
securing the frame 12 of the uppermost covers 10 along the top edge of
the support surface 100. In the alternative, and depending on the
configuration of the support surface 100, it may be desirable to form a
continuous barrier over a top edge of the support surface 100 as shown in
FIG. 7. As shown, one or more panels 14 of the uppermost covers 10 may be
extended over an edge of the support surface 100 to form one or more end
caps 26 covering the edge of the support surface 100. Each end cap 26 is
suitably comprised of a panel 14 having a first end attached to a frame
12 forming a joint with an adjacent cover 10 as described in detail
above. A second end of the panel 14 suitably extends over the top surface
and attaches on an opposing rear surface via securing means 20 forming
end caps 26. A sealant may also be applied to the end caps 26 along the
space between adjacent panels 14 as desired. In one embodiment, the end
cap 26 may include two bends, as shown in FIG. 7. Alternatively, the end
cap 26 may be rounded off, or rise to a pointed edge.

[0078]Not only is the present cover 10 operationally configured to secure
to a planar support surface 100, the cover 10 may also be secured to a
non-planar support surface 100. For example, a cover 10 may be secured
along an outside corner of a support surface 100--as encountered when
forming a continuous barrier across two or more sides of a building
exterior. FIG. 8 illustrates a cross sectional view of an embodiment of a
rectangular cover 10 secured to an outside corner of a support surface
100. As shown, the cover 10 can be bent to an angle substantially similar
to the bend angle of the outside corner. Although not necessarily limited
to a particular bend radius, a suitable panel 14 may comprise a bending
radius up to about fifteen times the thickness of the panel. Thus, the
cover 10 described herein can be bent from about 30° to about
150°. As exemplified in FIG. 8, the outside corner and
corresponding cover 10 each comprise a bend angle of approximately
90°.

[0079]As FIG. 8 further illustrates, a cover 10 is suitably secured to an
outside corner of a support surface 100 in similar fashion as covers 10
secured to relatively flat support surfaces 100. In one embodiment, a
cover 10 may be centered on the outside corner of a support surface 100
whereby the panel first surface 15a comprises equidistant perpendicular
faces, and the opposite ends of the frame 12 are secured to the support
surface 100 substantially the same distance from the outside corner--as
shown in FIG. 8. In another embodiment, the panel first surface 15a may
include perpendicular faces of different lengths. In another embodiment,
the corner of the panel 14 may be rounded off. In still another
embodiment, the panel 14 may include two bends providing a panel first
surface 15a having three faces--effectively cutting off the corner.

[0080]As FIG. 9 illustrates, the present cover 10 may also be secured to
an inside corner of a support surface 100--as encountered when forming a
continuous barrier at a soffit or an inside corner of a wall. Suitably,
adjacent covers 10 are secured to an inside corner at interfacing support
surfaces 100, wherein one end of a frame 12 of a first cover (listed as
10A) is secured to a first support surface 100-A as described above and
secured to a second support surface 100-B at a second end effectively
covering the inside corner of the support surface--as shown in FIG. 9. In
this embodiment, the panel 14 of cover 10A does not include a return
portion at the second end, but instead attaches directly to the first
surface of the main body 12a forming a joint between adjacent covers 10A
and 10B on support surface 100-B. In an alternative embodiment, a joint
may be formed between adjacent covers 10A and 10B on support surface
100-A.

[0081]In certain instances, a support surface 100 may include one or more
second protruding surfaces 200 at a particular point on an otherwise
substantially flat support surface 100. Typical protruding surfaces
include, but are not necessarily limited to door frames or jambs, window
frames or jambs, entry openings, and presentation ways. To effectively
form a continuous barrier across the support surface 100, it may be
necessary to secure a plurality of covers 10 along the outer perimeter of
the protruding surface 200.

[0082]FIG. 10 illustrates a simplified joint formed between a cover 10 and
a protruding surface 200. As shown, a cover 10 can be mounted close to
flush against a corresponding protruding surface 200. Unlike the
embodiment for covering an inside corner as described above, here a
second panel 14a can be inserted at the joint to cover the corner
junction between the support surface 100 and protruding surface 200. As
shown, the second surface 13b of a frame 12 can be set to interface the
second panel 14a whereby a securing means 20 can be inserted through both
the frame 12 and the second panel 14a to secure the cover 10 and seal
part of the joint. The non-secured portion of the second panel 14a can
then be sealed to the protruding surface 200 via a sealant 40.

[0083]An advantage of the cover 10 described herein includes that any
particular number of covers 10 may be used to form a continuous barrier
on a particular support surface 100 by first determining (1) the total
surface area of the support surface 100 and (2) the size and shape of
cover 10 to be used. Thus, in one embodiment, a total of one hundred
square foot covers 10 can be aligned in ten rows of ten covers 10 across
a 10 foot--10 foot support surface 100 to form a continuous barrier on
the support surface 100. In another embodiment where a smaller cover 10
is desired, a total of two hundred six inch square covers 10 can be
aligned in twenty rows of twenty covers 10 across a 10 foot×10 foot
support surface 100 to form a continuous barrier on the support surface
100. In another embodiment, covers 10 having right triangles can be used
to form a continuous barrier on the support surface 100--as seen in FIG.
11.

[0084]As illustrated in FIG. 12, a combination of non-uniform shaped
covers 10 can be used to form a continuous barrier on the support surface
100. In this embodiment, no two cover 10 center points are necessarily
aligned along similar horizontal or vertical rows/columns. Yet, a
continuous barrier may be formed on the support surface 100 nonetheless
based on the independent securability and sealability of the individual
covers 10. In this embodiment, persons may pre-mark or outline the
support surface 100 with various shapes of varying sizes on the support
surface 100 using chalk and the like. Corresponding covers 10 can then be
assembled and placed on the support surface 100 to cover each of the
distinct pre-marked areas. Thus, the cover 10 described herein is not
limited to any one particular aesthetic presentation on a support surface
100.

[0085]In similar fashion, one or more covers 10 may be secured to a
support surface 100 along a non-level base surface 110--as FIG. 13
illustrates. The independent securing of individual covers 10 to a
support surface 100 is therefore an advantageous feature of the present
application because it allows a user to construct a cover 10 of any size
and shape on-site necessary to cover a non-uniform or otherwise
unexpected exposed support surface 100 configuration.

[0086]As mentioned above, a sealing member may be disposed between the
cover 10 and the support surface 100 as desired. Suitably, a gasket
material may be employed that is operationally configured to cover at
least the second surface 13b when the cover 10 is secured to a support
surface 100, thereby forming a vapor barrier along the perimeter of the
cover 10 resistant to penetration by water and other fluids. In one
embodiment, a gasket is applied to a support surface 100 prior to
securing the cover 10 to the support surface 100, wherein the gasket may
be placed on the support surface 100 in an orientation corresponding to
the desired orientation of the cover 10 on the support surface 100.
Alternatively, a gasket may be applied to the second surface 13b of a
frame 12 prior to securing the cover 10 to the support surface 100. In
one suitable embodiment, a gasket material may be applied to either the
support surface 100 or second surface 13b via a "peel and stick"
technique. It is herein contemplated that a vapor barrier may also be
formed by applying one or more sealants to either a support surface 100
or second surface 13b in addition to, or in place of a gasket material.

[0087]A suitable gasket material includes, but is not necessarily limited
to a weather resistant material such as rubber, a synthetic rubber such
as neoprene, elastomer, structural silicone. A suitable elastomer
includes but is not necessarily limited to a thermoplastic elastomer such
as Santoprene®. A suitable sealant includes, but is not necessarily
limited to caulk made from silicone, polyurethane, polysulfide,
sylil-terminated-polyether or polyurethane, and acrylic sealant. A
sealant may also be applied to each of the joints described above to
further seal the support surface from the ambient environment. A suitable
joint sealant includes but is not necessarily limited to the caulk
materials listed above.

[0088]It is herein contemplated that the cover 10 may be secured to
various exterior and interior support surfaces 100 including, but not
necessarily limited to plywood, sheetrock, tin, brick, concrete, metal
and plasterboard. Thus, one or more covers 10 may be mounted on a support
surface 100 as cladding, used to seal asbestos within a support surface
100, used as decorative wall coverings, used as column covers, and as
covers for monoliths.

[0089]The cover 10 may be assembled on-site as described above and then
secured to a support surface 100 by one or more individuals. In a
simplified illustration, a user may (1) place an individual cover 10
against a support surface 100 at a target location, (2) align a
conventional screw at a point along the scored region 30 of the cover 10,
(3) use a common drill to insert the screw into the support surface 100,
(4) repeat steps 2 and 3 until a desired number of screws are securing
the cover 10 to the support surface 100. A second cover 10 can then be
secured to the support surface 100 by repeating steps 1 through 4. The
second cover 10 may be set adjacent the first cover 10, or in the
alternative, set apart from the first cover 10 on the support surface
100.

[0090]The invention will be better understood with reference to the
following non-limiting example, which is illustrative only and not
intended to limit the present invention to a particular embodiment.

EXAMPLE 1

[0091]In one non-limiting example, a one foot square architectural cover
10 is assembled having the following properties:

[0092]As will be understood by those of ordinary skill in the art, and
others, many modifications may be made without departing from the spirit
and scope of the invention. The embodiments described herein are meant to
be illustrative only and should not be taken as limiting the invention,
which is defined in the following claims.